Facility planning and Design Lecture 1 A

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Facility planning and Design Lecture 1 A
introduction

• Dr. Husam Arman

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Outline

• Syllabus
• Course contents
• ILOs
• Text book
• Grading
• Subjects detail
• Introduction to the course

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Syllabus
This course covers various areas related to
facility planning and design. The materials
covered include mainly three parts facility
location, plant layout and material handling. The
first two parts will be discussed extensively,
while little emphasis on the materials handling
part (see detail subjects).
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ILOs

1. Understand the importance of facility planning as
   an IE.
2. Be able to formulate quantitative and qualitative
   models to address facilities planning problems
3. Be able to analyze practical problems considering
   the fundamental principles of material handling
4. Be able to design a factory layout incorporating
   product, process, and schedule.
5. Be able to work in a team and confident in
   presenting and defending his work

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Text book

• Text book
• Facilities Planning, J.A. Tompkins et al., John
  Wiley Sons, Inc., New York, 2010
• Additional references
• Facility layout and location, Francis, McGinnis
  White, Prentice Hall NJ, 1992.
• Facilities Planning and Design, Alberto
  Garcia-Diaz and J. MacGregor Smith, Prentice
  Hall, 2007
•  

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Assessment criteria
Midterm Exams 40
Project 20
Final Exam 40
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Subjects detail
Week Subject
1 Introduction to Facilities Planning
2 Strategic Facilities Planning
3 Rectilinear-Distance Facility Location Problems (Single and Multi-facility)
4 Rectilinear-Distance Facility Location Problems (Single and Multi-facility)
5 Euclidean-Distance Facility Location Problems (Single and Multi-facility)
6 Euclidean-Distance Facility Location Problems (Single and Multi-facility)
7 Product, Process and schedule design
8 Flow systems, activity relationships and space requirements
9 Layout planning models
10 Layout planning models
11 Locations and Layout using computer
12 Product layout
13 Material Handling
14 Personnel requirements
15 Selecting the facility plan
16 Manufacturing systems
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Group Project

• Study a real location or layout problem and try
  to improve upon the current situation using
  analytical tools developed in the course.
• You are free to suggest a project that interests
  you
• More information will be provided duly!

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Project Planning

• Group Project will incorporate
• Course content
• Teamwork
• Data collection and analysis (will use software)
• Project Presentation
• Project Report

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Our ground rules

• Please switch off/silent our phones when in
  class.
• Arrive on time
• Keep our presentations to agreed upon lengths
• In general be courteous to others
• .
• Do you want to add anything!

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Ok, shall we start now!
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Facility location and plant layout

• The location of facilities and also
  determination of the configuration at certain
  types of facilities
• Also called Facilities planning!
• Facilities planning is complex and broad subject
  cuts across several disciplines (engineering,
  civil, electrical, architecture, etc)
• However, here well focus on industrial
  engineers role in developing effective and
  efficient facilities plans.

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Facilities Planning Viewpoints

• Civil engineering
• Electrical
• Mechanical engineering
• Architectural
• Real estate
• Urban planning
• Industrial engineering
• What is the role of each in facility planning?

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IE Viewpoint of Facilities Planning

• IEs are focusing on requirements, resource
  allocation, and efficient use of resources.
• Facilities are the integration of many lower
  level systems
• Space requirements with respect to flow and
  operations control
• Personnel requirements
• Equipment requirements
• System design/layout with respect to flow and
  operations control
• The use of information systems and technology to
  increase effectiveness
• Movement within a facility
• Movement between facilities Location

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Definitions

• Facility location refers to the choice of region
  and the selection of a particular site for
  setting up a business or factory
• Plant layout Plant layout refers to the
  arrangement of physical facilities such as
  machinery, equipment, furniture etc. within the
  factory building in such a manner so as to have
  quickest flow of material at the lowest cost and
  with the least amount of handling in processing
  the product from the receipt of material to the
  shipment of the finished product

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Definitions

• Facilities Planning determines how an activitys
  tangible, fixed assets should contribute to
  meeting the activitys objectives .
• This course will focus on facilities planning.
• Emphasis on location and layout.
• Some coverage of materials handling.

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Facilities planning
Facilities location
Facilities planning
Facilities design
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Why matters?

• To stimulate your thought, think of the following
  questions
• What impact does facilities planning have on
  handling and maintenance costs?
• What impact does facilities planning have on
  employee moral?
• What impact does facilities planning have on
  management of a facility?
• What impact does facilities planning have on a
  facilitys capability to adapt to change and
  satisfy future requirements?

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Why matters?
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Why matters?
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Facility Location in Location Strategy
.
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Why matters?

• All the facilities in the supply chain should
  have the following characteristics
• Flexibility
• Modularity

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Why matters?
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Strategic Planning

• Def.
• High level of planning
• Identify a process to obtain an objective
• Identify and utilize resources (physical aspects)
• Identify and execute processes (time aspects)
• Identify and coordinate methods (control aspects)
• Longer term (Strategic) vs. shorter term
  (Tactical)
• Plan a trip from Nablus to London (map?)
• Resources
• Timing
• Control
• Strategic and Tactical relationship
• Objective of strategic plan doesnt change!

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Strategic Planning

• Applied to Facilities Planning
• Requires an understanding of feasibilities
• Marketing
• Product development
• Manufacturing / Processing
• Production / Inventory control
• Human resources
• Finance
• Impacts the performance of each, too
• Concurrent design process seems best
• Facilities planning occurs simultaneously
• Evolving requirements
• Multiple alternatives
• Design iterations probable

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Steps in Engineering Design

• Ideal Sequence
• Defining the Problem
• Gathering Pertinent Information
• Generating Multiple Solutions
• Analyzing and Selecting a Solution
• Testing and Implementing the Solution
• Actual process is iterative
• Frequently back-track to a previous stage

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Facilities Planning Process Steps

• Defining the Problem
• Define
• Gathering Pertinent Information
• Specify
• Determine
• .

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Facilities Planning Process Steps

• Generating Multiple Solutions
• Generate
• Analyzing and Selecting a Solution
• Evaluate
• Select
• Testing and Implementing the Solution
• Implement the facilities plan
• Maintain and update the facilities plan

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Facilities Planning Process Steps

• Frequently back-track to a previous stage
• Update the products and redefine the objective of
  the facility

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Data for Strategic Facility Design

1. What is to be produced?
2. How are the products to be produced?
3. When are the products to be produced?
4. How much of the product is to be produced?
5. How long will the product be produced?
6. Where are the products to be produced?

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Example Data for Strategic Facility Design

• What is to be produced?
• 1/16 scale models of new and old tractors
• How are the products to be produced?
• Die sand casting, trimming/drilling,
  painting, assembling, direct shipping
• When are the products to be produced?
• Within 1/2 month prior to introduction, and 2
  months after order
• How much of the product is to be produced?
• Batch production runs of 100 to 1000, 8 new
  20 total models/yr
• How long will the product be produced?
• 2 3 yrs/model, product lifecycle of 15 30
  yrs, facility life gt50 yrs
• Where are the products to be produced?
• Small, rural Iowa town ( 3000 pop. supplied
  from Chicago, WI adjacent to rail, near major
  U.S. highway OEMs in IL, WI, IA

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Issues Impacting a Strategic Facilities Plan

• Number, location, sizes of warehouse/distribution
  centers
• Centralized vs. decentralized storage /
  manufacturing
• Acquire existing (brownfield) vs. build new
  (greenfield)
• Flexibility required for marketing technology
• Interfacing storage and manufacturing
• Level of vertical integration
• Control of materials and equipment
• Inbound and outbound material movement
• Technology changes for suppliers, firm, customers
• Financial goals for the design of the facility

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